[Oldjeep]

Question - where does the oil level sender mount? Behind headers?

 

[WRXer]

Vertically in the bottom of the oil pan between the sight window & oil filter.

 

[WRXer]

Replacement harnesses. Headlight harness, main harness, injector harness, & tail light harness complete with bonus tail light. The ignition switch, side stand switch, & handlebar controls were spared.

As mentioned all the battery / ground / starter cables were replaced also but not pictured.

Replaced the spark plugs since I had once in a lifetime access...once they were out had the same impression as when I did the <other bike>...is this really necessary?

They look black in the pics but in person they look good, should be running just fine.

 

[WRXer]

Installed the new main harness & have begun layering all the wires & hoses back in with many more yet to go. The dozens of photos I took during disassembly are invaluable.

 

[fjrlee]

I would remove and blank off the AIS system, remove and dismantle/clean out the starter motor then spray the rusty body of it. Great work done.

 

[WRXer]

Thought about removing the AIS but decided to leave it.

 

[WRXer]

Got the cooling system & all the wires that reside under the left & right main fairings reinstalled & sorted. Can't fill the cooling system yet since there is a loop that runs thru the throttle bodies. Those left & right wiring bunches & hoses snaked around each other & the surrounding frame to radiator cowling will test you. The headlight harness & handlebar controls feed in thru the steering head & tie in to the remaining connectors under the tank then the AIS hoses plop on top last. Had enough wiring & cable routing for now--moving on to suspension for a change of pace.

 

[WRXer]

Haz replacement seats (stock). I must be an optimist.

Rear suspension on after buying gigantic allen/hex drive (19mm) & regular (36mm) sockets.

Front suspension getting new oil--that old stuff stunk 🤮:

 

[FJRex]

Can't wait to see the finished product.

 

[WRXer]

After letting the fork drain for a few weeks (not intentional) I filled each leg with a few ounces of fresh fluid, cycled them for a few minutes, drained them again, then filled them up for good. One upper tube had a single rust pit spec on it in the travel portion, so I dressed it down with emery cloth.

Swapping out the mouse eaten rear fender & air box for fresh ones.

 

[WRXer]

The gauge buttons are supposed to look like this:

The mice chewed mine so they look like this:

In addition to no longer being weather tight the rubber caps now no longer activate the switches below that look like this (& seem to function fine):

I REALLY do not want to buy a used cluster for around $60 just to pry out the rubber buttons. Anyone know a source to get replacement buttons?
One in one out

Back

Front

 

[WRXer]

Dismounted the rotors & scrubbed them with water & a Scotch-Brite. Same with the pads (all interstate use, barley used). Cleaned the calipers, pad springs, & wheels with wheel cleaner. Tires only after I hear it run.

Bled front brake & clutch.

Letting the rear diff drain for a few days.

 

[RaYzerman]

Not awful but that rear diff hasn't been drained for a couple of years or more...... all good.

 

[fjrlee]

Coming along nicely - anticipation building here for the startup.

 

[StreamRider]

Dismounted the rotors & scrubbed them with water & a Scotch-Brite. Same with the pads (all interstate use, barley used). Cleaned the calipers, pad springs, & wheels with wheel cleaner. Tires only after I hear it run.
View attachment 90304

Bled front brake & clutch.

View attachment 90303

View attachment 90305

Letting the rear diff drain for a few days.

View attachment 90306

How did you get the two blue caliper star bolts so clean?

 

[WRXer]

Just my go to wheel cleaner. It does an amazing job on brake dust. I prefer to remove the pads then spray down the calipers, let them soak a couple minutes, hit with a toothbrush (If needed), then rinse off.

 

[FJ Rick]

Super restoration performance. We gotta ensure that these bikes are still around for the next generations to enjoy and you’re really doing your part with an abundance of valor

 

[StreamRider]

Super restoration performance. We gotta ensure that these bikes are still around for the next generations to enjoy and you’re really doing your part with an abundance of valor

I can second this as I AM that next generation and I am currently (well not at this freezing moment) enjoying the heck out of my 2003.

 

[FJ Rick]

I can second this as I AM that next generation and I am currently (well not at this freezing moment) enjoying the heck out of my 2003.

Yeap, do enjoy the heck out of what you’ve got and lose any guilt you may harbor for piling up the miles. Otherwise it’s just like abstaining and keeping your girlfriend tight for the next guy.

 

[SkooterG]

Wow. That is very impressive how clean you are getting that thing.